SOLDERING, BRAZING & WELDING

INTRODUCTION Some products cannot be manufactured as a single piece. The desired shape and size of such products can be obtained by joining two parts of same or different materials. These parts are manufactured individually and are joined together to obtain the desired product. For example, aircraft and ship bodies, welded machine frames, furniture, computers, bridges and the transmission or electric towers etc., are all fabricated by joining several different parts.
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Classification of joining processes: Temporary Joint Permanent Joint

A temporary joint can be easily dismantled separating the original parts without any damage to them
In case it is a permanent joint, an attempt to separate the parts already joined will result in the damage of the parts. In a permanent joint, the joint is made such that it has properties similar to the base metal of the two parts. These parts cannot be separated into their original shape, size and surface finish
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Based on the process used for making the joint, the joining processes can be further classified as: Soldering.
Brazing. Welding. Mechanical Fasteners - bolts, nuts, rivets, screws Adhesive bonding.
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Welding is one of the most extensively used fabrication method. The joint strength obtained in welding is being equal to or some times more than that of the parent metal. Welding is not only used for making structures, but also for repair work such as the joining of broken castings. The choice of a particular joining process depends on several factors such as application, nature of loads or stresses, joint design, materials involved and size and shape of the components
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WELDING

Welding is a process of metallurgical joining of two pieces of metals by the application of heat with or without the application of pressure and addition of filler metal. The joint formed is a permanent joint. It is extensively used in the fabrication work in which metal plates, steel sections, castings of ferrous metals are joined together. It is also used for repairing broken, worn-out or defective metal parts.
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Modern methods of welding may be classified under two broad headings. Plastic or pressure welding process Fusion or non-pressure welding process
In plastic or pressure welding process the pieces of metal to be joined are heated to a plastic state and then forced together by external pressure. This procedure is used in forge welding, resistance welding, spot welding in which pressure is required.

 In the fusion or non-pressure welding, the material at the joint is heated to a molten state and allowed to solidify. This includes gas welding, arc welding

The surfaces of the metal which are to be joined by any of the welding processes must be sufficiently clean to permit clean metallic surfaces to come in to contact.
Fluxes are applied to the parts being welded to dissolve the oxides or to prevent the formation of oxides.

GENERAL WELDING PROCEDURE 1. Surface Cleaning: Surfaces of the parts to be welded need to be thoroughly cleaned to remove dust, dirt, oil, grease etc. 2. Edge Preparation: Preparing a contour at the edges of the pieces to be joined. It may involve beveling or grooving. This is done in order to get the fusion or penetration through the entire thickness of the member.

3. Clamping: Pieces to be welded are clamped suitably so that there are no undesirable movements during welding. 9

4. Safety Devices: Goggles & shields to protect the eyes, Apron to prevent the sparks and flying globules of molten metal, shoes, hand gloves etc. 5. Initial Weld: Initial tack welds are done at the opposite corners of the joint to secure the pieces together. Any cracks at this stage must be removed as they cause residual stresses. 6. Intermediate and Final Welding: The weld joint is formed through various weaving movements (weld beads). During this process, filler metal and a suitable flux are used. After the intermediate run of welding, final run is taken. 10

7. Removal of Excess Material: Extra material on the weld surface can be removed using tongs and chipping hammer. The weld is allowed to cool and then cleaned.

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Classification of welding processes:

(i). Arc welding Carbon arc Metal arc Metal inert gas Tungsten inert gas Plasma arc Submerged arc Electro-slag (ii). Gas Welding
Oxy-acetylene Air-acetylene Oxy-hydrogen (iv)Thermit Welding (v)Solid State Welding

Friction Ultrasonic Diffusion Explosive

(vi)Newer Welding Electron-beam Laser (vii)Related Process Oxy-acetylene cutting Arc cutting Hard facing Brazing Soldering

(iii). Resistance Welding Butt Spot Seam Projection Percussion

 Another criterion used for a classification of the welding process is based on the composition of the joint (i) autogeneous (ii) homogeneous, and (iii) heterogeneous In autogeneous processes no filler material is added during the joining. All types of solid phase welding and resistance welding are examples of this category. In homogeneous welding processes, the filler material used to provide the joint is the same as the parent material. Arc, gas, and thermit welding belong to this category In third category of welding, a filler material different from the parent material is used. Soldering and brazing are two such joining processes

GAS WELDING

Gas welding is a fusion welding process Flame produced by the combustion of gases is employed to melt the metal

The molten metal is allowed to flow together thus forming a solid continuous joint upon cooling.
By burning pure oxygen in combination with other gases, in special torches, a flame up to 33000C can be attained.
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Principle
In oxy-fuel gas welding (OFW) the heat is obtained from the combustion of a fuel gas such as acetylene in combination with oxygen The process is a fusion welding process wherein the joint is completely melted to obtain the fusion. The heat produced by the combustion of gas is sufficient to melt any metal and as such is universally applicable The fuel gas generally used is acetylene because of the high temperature generated in the flame. This process is called oxy-acetylene welding

Principal Cont.

Oxy-acetylene Gas Welding Equipment

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Oxy-acetylene Gas Welding Equipment

1. 2. 3. 4. Welding torch & tip An acetylene cylinder 15.5 bar, red or maroon An oxygen cylinder 125 bar. Blue or black Pressure regulator Cylinder pressure to delivery pressure 5. Pressure gauge- One shows cylinder pressure & the other shows the working or delivery pressure 6. Rubber hoses - black/green hose for oxygen & red/orange hose for acetylene 7. Safety devices Goggle with coloured glasses, hand gloves, helmet, apron, sleeves, shoes etc.
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The oxy-acetylene flame is used to pre heat the parts to be welded around the joint and also to melt the filler metal.

A jet of oxy acetylene flame issuing from the nozzle of a burner is played on the junction of the two pieces to be welded. At the same time a filler rod is held in the zone of jet and its melt is deposited on the fused junction.
A weld is obtained after the molten metal solidifies. The coating on the filler rod acts as a flux to keep the joint clean.
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GAS WELDING FLAMES (OXY-ACETYLENE FLAMES) (Based on Gas Ratio) 1. Neutral Flame: (Gas ratio is 1)

.A certain amount of oxygen is required for complete combustion of fuel gases When the oxygen supply varies, the flame appearance obtained would also vary. In neutral flame all the acetylene present is completely burned and thus all the available heat in the fuel gas is released.

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So this is the most desirable flame to be used in oxy-acetylene welding. Due to neutral flame no chemical change and no oxidation in molten metal This neutral flame is desired for most welding operations. Used for welding steel, stainless steel, cast iron, Cu etc.

2. Carburizing or Reducing Flame: ( Gas ratio 0.95 to 1) Excess of acetylene is present, Low temp flame The excess unburnt carbon is absorbed in ferrous metals, making the weld hard and brittle. An intermediate flame feather exists - reddish in colour.

The length of the flame feather is an indication of the excess acetylene present.
Carbonizing flame is used for welding high carbon steels and cast iron, alloy steel.
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Since this flame provides a strong reducing atmosphere in the welding zone, it is useful for those materials which are readily oxidize like oxygen free copper alloys. It is also used for high carbon steels, cast iron and hard surfacing with high speed steel and cement carbides.

2. Oxidizing Flame: (Gas ratio 1.15 to 1.5) Excess of oxygen is present, similar to the neutral flame Inner white cone is some what small, giving rise to higher tip temperatures. Excess of oxygen causes the metal to burn/oxidize quickly. Used for brass, bronze Widely used for oxyacetylene cutting and not suitable for welding since the weld metal will be oxidised.

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Advantages of Oxy-acetylene Gas Welding

1.The equipment is inexpensive, simple and is easily portable and versatile

2.The same equipment with a range of torches can be used for oxygen cutting as well as for brazing
3. Source of heat is separate from the filler rod, filler metal and heat can be properly controlling, giving rise to satisfactory result. 4. Gas flame temperature is lower and easy controllable which is necessary for the delicate work. Therefore it is extensively used for sheet metal fabrication

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Disadvantages of Oxy-acetylene Gas Welding

1. Equipment must always be handled carefully as in certain circumstances acetylene is explosive as oxygen when used in an oily atmosphere (such as an old dirty garage floor pit). 2. A high temperature flame from a hand held torch is dangerous when handled carelessly. 3. It is much slower than electric arc welding and does not concentrate the heat close to the weld. Thus, the heat treated area is larger, which causes more distortion. 4. Highly skilled operators are required to produce a good weld. 5. If electric arc welding is available gas welding is seldom used for work over 3.2mm thick. 6. The process is not satisfactory for heavy sections
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Applications:
For joining of thin materials. For joining materials in whose case excessively high temperature or rapid heating and cooling of the job would produce unwanted changes in the metal. For welding both ferrous and non-ferrous metals. In automotive &aircraft industries, project site works, workshops etc.

GAS WELDING
Oxygen-Hydrogen Welding The oxygen-hydrogen torch can reach temperatures much higher than the oxy-acetylene torch. More expensive than oxy-acetylene welding and involves the flammability risk with hydrogen.

Plasma Welding Hydrogen plasma burns even hotter than hydrogen gas, permitting the welding of extremely high-melting-point metals. Very clean procedure that results in very little slag or foreign matter in the weld.

IT 208

Chapter 14

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Gas Cutting
It is possible to rapidly oxidise (burn) iron and steel when it is heated to a temperature between 800 to 10000 C When a high pressure oxygen jet with a pressure of the order of 300 KPa is directed against a heated steel plate, the oxygen jet burns the metal and blows it away causing the cut This process is used for cutting steel plates of various thicknesses (can go up to 2 m) mainly because the equipment required is simple and can be carried anywhere without handling the heavy steel plates.

 Here the torch tip has a provision for preheating the plate as well as providing the oxygen jet. Thus the tip has a central hole for oxygen jet with surrounding holes for preheating flames

GAS CUTTING

Manual Gas Cutting

Arc Welding Equipments

Arc Welding Setup

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ARC WELDING

Joining of metals with heat produced by an electric arc. Heat necessary to melt the edges of the metal to be joined is obtained from an electric are struck between the electrode (filler rod) and the work, producing a temperature of 50000C, in the welding zone. The heat of the arc melts the base metal or edges of the parts fusing them together.
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Filler metal, usually added melts and mixes with molten base metal to form the weld metal.
The weld metal cools and solidifies to form the weld.

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What is an Electric Arc?

An arc is an electric current flowing between two electrodes through an ionized column of gas. It is sustained by an ionized column of gas (plasma) through which the current flows To initiate the arc in AW, electrode is brought into contact with work and then quickly separated from it by a short distance

ARC WELDING MACHINE: AC or DC

AC Arc Welding Machine:

A step down transformer - receives the AC supply between 200 to 440volts and transforms it to the required low welding voltage in the range of 80 to 100volts.
A high current of 100 to 400A will be suitable for general arc welding work. In AC arc welding, there is no choice of polarity since they change in every cycle.
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DC Arc Welding Machine: In DC welding, the workpiece is connected to the

positive pole of a DC generator and the electrode to the negative pole in order to melt greater mass of the metal in the base material. This is called straight polarity. When the less heat is required at the base material, the polarity is reversed. This is called reversed polarity.

We can select the polarity depending upon the type of the job. Hence, in DC arc welding, it is possible to melt many metals which require more heat to melt.
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DC arc welding
it is generally preferred because of the control of the heat input offered by it. If more heat is required at the workpiece side, such as for thicker sheets or for the work materials which have higher thermal conductivity such as aluminium and copper, the workpiece can be made as anode, liberating large heat near it For thinner materials where less heat input is required in the weld zone, the polarity could be reversed by making the workpiece as negative

Sl No.
1. 2. 3. 4

Aspect
Arc Stability Cost Electrodes Electrical energy Consumption Efficiency Polarity

AC Welding
Lower/ Unstable Low Only Coated

DC Welding
Higher/Stable High Both Bare & Coated

Less energy consumption per More energy consumption kg of the metal deposited (3 per kg of the metal deposited to 4 kWh) (6 to 10 kWh) High No choice of polarity Low Straight or reversed polarity can be used depending on the type of job and heat required at the base metal

5. 6.

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ARC WELDING ELECTRODES

1. Consumable Electrodes: Melt along with the workpieces & fills the joint. They are either Bare or Coated. When the bare electrodes are used, the globules of the molten metal while passing from the electrodes absorb oxygen and nitrogen from the atmospheric air to form non-metallic constituents which gets trapped in the solidifying weld metal and thereby decreasing the strength of the joint.
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Coated Electrodes facilitate:

1. Protection of molten metal from oxygen and nitrogen of the air by providing a gaseous shield around the arc and the molten metal pool. 2. To establish & maintain the arc throughout welding 3. The formation of slag over the joint, thus protects from rapid cooling.

4. Addition of alloying elements

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2. Non-consumable Electrodes:

When non-consumable electrodes are used, an additional filler material is also required. The advantage of using this type of electrode is that the amount of the metal deposited by the filler rod can be controlled.

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Advantages of Arc Welding 1.Applicable to an infinite variety of work & can be executed in any position. 2.It produces strong sound and ductile welds. 3.Satisfactory welds can be produced in heavy & light sections. 4.Low cost process & Low accuracy in setting up required. 5.Excellent joint properties can be obtained in mild, low alloy and stainless steels, nickel and copper-base alloys.
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Disadvantages of Arc Welding 1.Basically a manual process requiring adequate operator skill for good results. 2.Electrodes require frequent changing. 3.Multi run welds necessary on thick plate-slag chipping necessary after each run. 4.The principal disadvantage has been the high heat of the metal arc which makes it unsuitable for use on materials less than 1.55 mm thick. 5.High initial cost of welding equipment.
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The arc must be shielded because - as it hardens the molten metal combines with oxygen and nitrogen to form impurities that weaken the weld.

The electrodes are usually coated with a flux. This coating forms a gaseous cloud that shields the molten metal from the atmosphere.
The coating also forms a protective slag. The slag floats on the molten pool and hardens as the weld cools. This keeps impurities out of the weld.

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Arc Shielding
At high temperatures in AW, metals are chemically reactive to oxygen, nitrogen, and hydrogen in air
Mechanical properties of joint can be seriously degraded by these reactions To protect operation, arc must be shielded from surrounding air in AW processes

Arc shielding is accomplished by:

Shielding gases, e.g., argon, helium, CO2 Flux

Flux
A substance that prevents formation of oxides and other contaminants in welding, or dissolves them and facilitates removal Provides protective atmosphere for welding Stabilizes arc Reduces spattering

Various Flux Application Methods

Pouring granular flux onto welding operation Stick electrode coated with flux material that melts during welding to cover operation Tubular electrodes in which flux is contained in the core and released as electrode is consumed

Shielded Metal Arc Welding (SMAW)

An arc welding process that produces a coalescence of metals by heating with an arc between a covered metal electrode and the work pieces Stick Welding Shielding is obtained from decomposition of the electrode covering. Filler metal is obtained from the electrode.

Shielded Metal Arc Welding

Figure 31.3 Shielded metal arc welding (SMAW).

Gas Metal Arc Welding (GMAW)

An arc welding process that produces coalescence of metals by heating them with an arc between a continuous filler metal (consumable) electrode and the work MIG welding Shielding is obtained entirely from an externally supplied gas or gas mixture.

GMAW Weld Diagram

Gas Metal Arc Welding (GMAW)

Uses a consumable bare metal wire as electrode and shielding accomplished by flooding arc with a gas Wire is fed continuously and automatically from a spool through the welding gun Shielding gases include inert gases such as argon and helium for aluminum welding, and gases such as CO2 for steel welding Bare electrode wire plus shielding gases eliminate slag on weld bead - no need for manual grinding and cleaning of slag

GMAW Advantages over SMAW

Better arc time because of continuous wire electrode
Sticks must be periodically changed in SMAW

Better use of electrode filler metal than SMAW

End of stick cannot be used in SMAW

Higher deposition rates Eliminates problem of slag removal Can be readily automated

Submerged Arc Welding (SAW)

Uses a continuous, consumable bare wire electrode, with arc shielding provided by a cover of granular flux Electrode wire is fed automatically from a coil Flux introduced into joint slightly ahead of arc by gravity from a hopper
Completely submerges operation, preventing sparks, spatter, and radiation

Submerged Arc Welding (SAW)

An arc welding process that uses an arc between a bare metal electrode and the weld pool. The arc and molten metal are shielded by a blanket of granular flux. a process in which welding is done by an automatic electrode feeding machine wherein the tip of the electrode is submerged into a granular flux which shields the arc and the molten metal.

SAW operations

SAW Applications and Products

Steel fabrication of structural shapes (e.g., I-beams) Seams for large diameter pipes, tanks, and pressure vessels Welded components for heavy machinery Most steels (except high C steel) Not good for nonferrous metals

Non-consumable Electrode Processes

Gas Tungsten Arc Welding Plasma Arc Welding Carbon Arc Welding Stud Welding

Gas Tungsten Arc Welding (GTAW)

An arc welding process that produces coalescence of metals by heating them with an arc between a tungsten (non-consumable) electrode and the work piece. TIG welding Shielding is obtained from an externally supplied gas or gas mixture.

GTAW or TIG process

Gas Tungsten Arc Welding (GTAW)

Uses a non-consumable tungsten electrode and an inert gas for arc shielding Melting point of tungsten = 3410 C (6170 F) Used with or without a filler metal
When filler metal used, it is added to weld pool from separate rod or wire

Applications: aluminum and stainless steel most common

Advantages / Disadvantages of GTAW

Advantages:
High quality welds for suitable applications No spatter because no filler metal through arc Little or no post-weld cleaning because no flux

Disadvantages:
Generally slower and more costly than consumable electrode AW processes

Plasma Arc Welding (PAW)

Special form of GTAW in which a constricted plasma arc is directed at weld area Tungsten electrode is contained in a nozzle that focuses a high velocity stream of inert gas (argon) into arc region to form a high velocity, intensely hot plasma arc stream Temperatures in PAW reach 28,000 C (50,000 F), due to constriction of arc, producing a plasma jet of small diameter and very high energy density

Plasma Arc Welding

Figure 31.10 Plasma arc welding (PAW).

Advantages / Disadvantages of PAW

Advantages:
Good arc stability Better penetration control than other AW High travel speeds Excellent weld quality Can be used to weld almost any metals

Disadvantages:
High equipment cost Larger torch size than other AW Tends to restrict access in some joints

Other Fusion Welding Processes

FW processes that cannot be classified as arc, or oxyfuel welding Use unique technologies to develop heat for melting Applications are typically unique Processes include:
Electron beam welding Laser beam welding Electroslag welding Thermit welding

Thermit Welding (TW)

FW process in which heat for coalescence is produced by superheated molten metal from the chemical reaction of thermite Thermite = mixture of Al and Fe3O4 fine powders that produce an exothermic reaction when ignited Also used for incendiary bombs Filler metal obtained from liquid metal Process used for joining, but has more in common with casting than welding

Thermit Welding

Figure 31.25 Thermit welding: (1) Thermit ignited; (2) crucible tapped, superheated metal flows into mold; (3) metal solidifies to produce weld joint.

TW Applications
Joining of railroad rails Repair of cracks in large steel castings and forgings Weld surface is often smooth enough that no finishing is required

Electroslag Welding (ESW)

Electroslag Welding is a welding process, in which the heat is generated by an electric current passing between the consumable electrode (filler metal) and the work piece through a molten slag covering the weld surface. Prior to welding the gap between the two work pieces is filled with a welding flux Electroslag Welding is initiated by an arc between the electrode and the work piece (or starting plate) Heat, generated by the arc, melts the fluxing powder and forms molten slag. The slag, having low electric conductivity, is maintained in liquid state due to heat produced by the electric current.

 The slag reaches a temperature of about 3500F (1930C). This temperature is sufficient for melting the consumable electrode and work piece edges. Metal droplets fall to the weld pool and join the work pieces.

Electroslag Welding is used mainly for steels.

 Advantages of Electroslag Welding

High deposition rate - up to 45 lbs/h (20 kg/h); Unlimited thickness of work piece. Disadvantages of Electroslag welding: Coarse grain structure of the weld; Low toughness of the weld; Only vertical position is possible.

Resistance Welding (RW)

A welding processes that use a combination of heat and pressure to accomplish coalescence Heat generated by electrical resistance to current flow at junction to be welded Principal RW process is resistance spot welding (RSW)

Principal
In resistance welding(RW), a low voltage(typically 1 V) and very high current(15000 A) is passed through the joint for a very short time (typically 0.25 sec)). This high amperage heats the joint, due to contact resistance at the joint and melts it. The pressure on the joint is continuously maintained and the metal fuses together under this pressure. The heat generated in resistance welding can be expressed as H=k* I2*R*t

Where H= the total heat generated in the work,J I=electric current,A t = time for which the electric current is passing through the joint,s R= resistance of the joint K=a constant to account for the heat losses from the welded joint The resistance of the joint, R is a complex factor to know because it is composed of a) the resistance of the electrode b)the contact resistance between the electrode and work piece c) the contact resistance between the two work piece plates d) the resistance of the work piece plates

Resistance Welding

Figure 31.12 Resistance welding, showing the components in spot welding, the main process in the RW group.

Components in Resistance Spot Welding

Parts to be welded (usually sheet metal) Two opposing electrodes Means of applying pressure to squeeze parts between electrodes Power supply from which a controlled current can be applied for a specified time duration

Advantages / Drawbacks of RW
Advantages: No filler metal required High production rates possible Lends itself to mechanization and automation Lower operator skill level than for arc welding Good repeatability and reliability Disadvantages: High initial equipment cost Limited to lap joints for most RW processes

Resistance Spot Welding (RSW)

Resistance welding process in which fusion of faying surfaces of a lap joint is achieved at one location by opposing electrodes Used to join sheet metal parts using a series of spot welds Widely used in mass production of automobiles, appliances, metal furniture, and other products made of sheet metal
Typical car body has ~ 10,000 spot welds Annual production of automobiles in the world is measured in tens of millions of units

Spot Welding Cycle

Figure 31.13 (a) Spot welding cycle, (b) plot of squeezing force & current in cycle (1) parts inserted between electrodes, (2) electrodes close, force applied, (3) current on, (4) current off, (5) electrodes opened.

Resistance Seam Welding (RSEW)

Uses rotating wheel electrodes to produce a series of overlapping spot welds along lap joint Can produce air-tight joints Applications:
Gasoline tanks Automobile mufflers Various other sheet metal containers

Resistance Seam Welding

Figure 31.15 Resistance seam welding (RSEW).

Resistance Projection Welding (RPW)

A resistance welding process in which coalescence occurs at one or more small contact points on parts Contact points determined by design of parts to be joined
May consist of projections, embossments, or localized intersections of parts

Resistance Projection Welding

Figure 31.17 Resistance projection welding (RPW): (1) start of operation, contact between parts is at projections; (2) when current is applied, weld nuggets similar to spot welding are formed at the projections.

Solid State Welding Processes

Forge welding Cold welding Roll welding Hot pressure welding Diffusion welding Explosion welding Friction welding Ultrasonic welding

Forge Welding
Welding process in which components to be joined are heated to hot working temperature range and then forged together by hammering or similar means Historic significance in development of manufacturing technology
Process dates from about 1000 B.C., when blacksmiths learned to weld two pieces of metal

Of minor commercial importance today except for its variants

Friction Welding (FRW)

SSW process in which coalescence is achieved by frictional heat combined with pressure When properly carried out, no melting occurs at contact surfaces No filler metal, flux, or shielding gases normally used Process yields a narrow HAZ Can be used to join dissimilar metals Widely used commercial process, amenable to automation and mass production

Friction Welding

Figure 31.28 Friction welding (FRW): (1) rotating part, no contact; (2) parts brought into contact to generate friction heat; (3) rotation stopped and axial pressure applied; and (4) weld created.

Applications / Limitations of FRW

Applications: Shafts and tubular parts Industries: automotive, aircraft, farm equipment, petroleum and natural gas Limitations: At least one of the parts must be rotational Flash must usually be removed Upsetting reduces the part lengths (which must be taken into consideration in product design)

Soldering
Soldering is a method of joining two metal work pieces by means of a third metal (solder) at a relatively low temperature, which is above the melting point of the solder but below the melting point of either of the materials being joined. Flow of the molten solder into the gap between the work pieces is driven by the capillary force The solder cools down and solidifies forming a joint. The parent materials are not fused in the process.

 Soldering is similar to Brazing. The difference is in the melting point of the filler alloy: solders melt at temperatures below 840F (450C); brazing filler materials melt at temperatures above this point. in the welding processes edges of the work pieces are either fused (with or without a filler metal) or pressed to each other without any filler material; soldering joins two parts without melting them but through a soft low melting point solder.

Traditional lead containing solders consist of tin (Sn) and lead (Pb).

Brazing
Brazing is a method of joining two metal work pieces by means of a filler material at a temperature above its melting point but below the melting point of either of the materials being joined. Flow of the molten filler material into the gap between the work pieces is driven by the capillary force. The filler material cools down and solidifies forming a strong metallurgical joint, which is usually stronger than the parent (work piece) materials. The parent materials are not fused in the process.

Brazing filler materials

Copper filler alloys: Used for brazing Copper alloys, steels, Nickel alloys. Aluminum filler alloys: Used for brazing Aluminum alloys.

Silver filler alloys: BAg-4 (40Ag-30Cu-28Zn-2Ni)

Used for most of metals and alloys except aluminum and magnesium alloys.

Weldability
Capacity of a metal or combination of metals to be welded into a suitably designed structure, and for the resulting weld joint(s) to possess the required metallurgical properties to perform satisfactorily in intended service Good weldability characterized by:
Ease with which welding process is accomplished Absence of weld defects Acceptable strength, ductility, and toughness in welded joint